High solids vinyl dispersions



mur y States Patent 2,946,702. THIGH sonms vn svr. DISPERSIONS .Henpy J., Bach, Mount Lebanon Township, Allegheny Couuty Bauassignor, by mesne, assignments,:.to AmericaniMarietta. Company, Steiner-Madge Ci. Division, Chicago, 111;, a corporation of'lllinois larly for coating metal surfaces, and to the resultant oa edlmetal articles.

: The: polyvinyl resins usually. employed .in coating and 'like;, co mpositions are dissolved, at solid. concentrations .of abput; 15 K112313013. 30.%,@in conventional solvent tmixtures-,. of ketoneand ester solvents, with. varyipg amounts of; liquid aromatic,hydrocarbn -diluents.;. In .order; to avoid excessively high viscosities,.the polyvinyl-resinsused in such compositions musthave.- relawtively dow molecular weight, generally below- 20.000. In o rder to avoid use of such large proportionsoflsolvents and to use higher molecular weight polyvinyl resins, ,which have superior qualities. of physicalstrength and. corrosion. resistance, and to obtain. a thicker. coat- .ing-withpne application of the compositiomotherforms of, coatin and like compositions havev beenxdeveloped known as dispersions, and more specifically. asorganosols and plastisols, in-whcih the high-molecular. weight polyvinyl resins are admixed with plasticizers and sometimes volatile liquid diluents (e.g., butyl ether of diethylene glycol). However, the preparation andapplication of such dispersions has presented a difiicult problem because, on the one hand, the use of a high percentage ofthe plasticizer component (ordinarily in the range of about 40% to about 150% of the resin .componentyreduces the physical strengthand hardness of-the-film formed'by-thecomposition, and, on

the othenhand, the. use. of. arelativelyalow. percentage of plasticizer, in order to obtain greater} film. strength, toughness, abrasionresistance andthe like,-jin:conjunc- .tion with a volatile diluent to assist in softening; and dispersinglthe resin, results in acomposition whicl'ijcannot beappliedat thicknesses of more. than .about 3.. mils -inza single application (measured. on ,th.e..cured film), without, developing filmblisters and likeimperfe'ctions, .caused ,by atherescaping. solventand .diluent,,,when baked attemperatures .of about 400 F..or,higher.,

or a mixture of such-resin. Such resins arewell known .in the art, and include the solid thermoplastic polymers and. copolymers.v derived. from vinyl chloride, alone, or

.. The... polyvinyl resin. dispersionsof the present, in-

vention arecapable. of being applied in alsingle app licatiomat thicknesses of as much, as 20 mils, tor-ex- 1 ample,- .and..'of. being. fused. at baking, temperatures of 400 F. or more, without developing film blisters or.

theJike. .The. dispersions of the invention. can be formuv.latedffor. application, at ,lesser, thicknesses, such: as a .inilpr, less. -Also, lower baking temperaturesfcan'be used,,. with, a corresponding increase in curing time.

The. coatings obtained in ,accordance withi the invenp 'tion haveless .thanthe ,usualfproportion of .plasticizer, and have superior qualitieso film1toughness, abrasion resistance. and the like; and high corrosion ,re'sistance. -T'The;dispersions-'of jthe invention form a.,toug l1 adher- .enbcoating, and are particularly useful in coatlngtsteel l'pipe and tubing,, flatsh'eet steel to be subsequently, fabricated intoQ-cans closures, screw caps, panels toys and other articles, 'and wire for electrical conductors .and other purposes. The corrosion resistance, oig'th'e coatera for various corrosive chemicals.

a ing points; withinthe boiling -range:z'ofifthetvolatil l -:per s ant componentlof f thewinventi'on.1 is a:

2,946,702 Patented July 26 .componentwhich. lowers. the viscosityof the dispersion for purposes of application, and assists in fusing the resin. component. atfusing. temperatures.-

The resin component of the dispersion of the inven- ,tion is a thermoplastic polyvinyl resin having -anaverage molecular. weight in excess of 2 0,0 00 (usually. not

over about 50,000, but extending to higher ranges of 100,0.0 0, for example, or more, without any upper; limit as regards operability for the purposes 'of-thisinvention), and made from vinyl chloride, in majorjamount (morefthan half of the total-constituentsofthe resin),

conjointly with vinylid'enechloride, organ esterjofT-viuyl alcohol (e.g., vinyl acetate). The present preferred exaxmple oftlie resin component of the dispersion of, the

invention is polyvinyl chloride, e.g., Geon 12,1 of B. F Goodrich Chemical.Co., Cleveland; Ohio, .aipoi1yvinyl chloride'resin havinga specific gravity offabout 1.4? and a specific viscosity of about'0.401(0.4% solution innitrobenzene at 20 C.). Other examplesjare copolymers .of'vinyl chloride (about by'weigli t) andvinyliacetate (about'5% by weight); having' s'pecific; gravities' of. about" 1.39 and specific. viscosities; of 30 about-1:53 in cyclohexanone at 20C.; and'the' Vi'nylite VYNVT series of resins of Union Carbide & carbon Corp, New York N.Y.', and".Geon 202of'B. F. Goodrich Chemical Co.,, a"vinyl chloride andfvinylidene chloride;cop.olymer"having'a specific gravity of 1i41 1and a specific viscosity of 81291310401 (0.4% solution in nitrobenzene at20" C.). I e I :Tlieplasticizer component of..the dispersion of their;- vention, maybe. any one or a mixture of a wide varietyf of f chemical I plasticizers commonly used. for I plasi 'i a' o ny es pqmpp s ibed-ab v e.g thealkyltand -'aryluerivatives of organicacids, such ,as phthalates, pelargpnates, glyconates,' sebacates; adipates, azelates, phosphates andcertaihplasticizing, petrlol'eum 'OiI'fI'QCliOIISUQThB" present preferred example ofitheplasticizer component is dioctyl phthalate biitfit is not critical'fonthepurposesof. the invention; Various..j single unmixedplaisticizers may be sejlectd f or special i applications, in order to obtain particular "fused jfilm properties such. as low temperature flexibilityp low flammability, water. resistance, and, the I like.

plasticizer volatility, non-migration, non toxi'city; non

The .volatile liquid dispersant component. ofv the dispersion. of the invention is composed of l'mixediiarom at ic alkyl substituted polynuclear hydrocarbons, having a jspe- ,cific, gravity of. about one, a mixed .aniliiie .pointj-ot about 26. Ito about 30 C., a, distillation range .(ASTMQ86- '5 2T of about 3 Q to about 450711,, anclfcharactrized by abiIity-toaid the'plasticizer'component'indispersing the resin component; andby ability to evaporate most --(preferably-about- '95 of its-weight -outof films ofthe composition ofi the invention when baked, for example, for a period ofiabout 5 minutes at 425 F. In order for such volatiliiation to take place in an even'progression, vqlatile thus avoiding blistering, it is==necessaryfor the liquid dispersant to.have 'sub'stantially evenly;increasing percentages by weight which-haveevenly increasing boildispersant. The;presenttpreferred' example-o h mixture iofjithe kind described, ofcoal tar; a a w F min ne.impregnate nan, Clairton, Pennsylvania. It and' other exarnples of the volatile liquid dispersant component of the invention which are hydrocarbon mixtures of the kind described, of coal tar origin, have the following characteristics based on typical analyses (Example A being the said DiPolymer Oil) TABLE I.VOLATILE LIQUID DISPERSANT EXAIVIPLES (b) Temperature C.) (1) Distillation range Ex. A Ex. 13 Ex. Ex. D

(0) Percent by weight boiling at stated temperature:

(2) Specific gravity at 15.5 C 0. 99 .98 1.00 .99 (3) Muted aniline point 28 26 27 30 For the purposes of the invention, the amount of the primary plasticizer component must be in the range of about 2% to about 25% of the combined weight of said primary plasticizer component and the resin component,

such range limits being necessary to obtain films having the quality sought for the purposes of the invention. The

volatile liquid dispersant component must be present in tional coating methods, such as spraying, roller coating,

dipping and brushing. The thickness of the fused coated film which may be deposited in a single application may be varied by adjusting the viscosity of the composition, by adjusting the proportions of the plasticizer or volatile liquid dispersant component, or both, and coating thicknesses can thus be obtained ranging from less than 1 mil to more than 20 mils. Such coatings are notably strong, hard and unblistered, and essentially free of the volatile liquid dispersant component, after being sufiiciently baked; e.g., for 5 minutes at 425 F. The baking temperature should be at least about 400 F., but can be increased virtually without limit by suitable control of the baking time.

The baking time can be reduced in the case of the thinner coatings, and can be reduced as the baking temperature is increased. Even the thickest of the above-mentioned films are free of blisters, pits, film cracking and similar film imperfections of the kind caused by conventional volatile diluents.

The following Table 11 illustrates examples of compositions of the invention, and their properties when applied and baked on specimens of primed blackplate:

4 The invention is further illustrated in the following examples:

Dispersion Example I A dispersion consisting of 43.0 parts by weight of high molecular weight polyvinyl chloride resin (Geon 121"), 8.8 parts of plasticizer (dioctyl phthalate), 44.4 parts of volatile liquid dispersant (DiPolymer Oil) and 3.8 parts of a suitable thermal stabilizer (Trimal of National Lead Co.) is prepared by stirring 15 minutes on a conventional drill press type stirrer. The resulting dispersion has an initial viscosity of about 100 seconds in #4 Ford cup at F. This dispersion is roll coated over primed sheet steel and tin plate at 11.5 mils thickness (measured dry) and baked 10 minutes at 425 F. Commercial cans fabricated from the coated plate and test packed with a large variety of chemical products, display excellent corrosion resistance.

Dispersion Example 11 A small section of steel pipe is preheated to about 300- 400 F. and, while hot, spray coated with the dispersion prepared as in Example I, to a fused film thickness of 9 mils, and baked 10 minutes at 425 F. The coating thus applied is tough, abrasion resistant, and free of blisters, cracks and other visible film defects.

The resin dispersion of the invention is preferably applied to metal surfaces, such as tin, steel and aluminum,

which have first had a primer coating applied and baked thereon. Conventional primers can be used, such as those shown in the examples of Gray, et al. Patent No. 2,324,078, but it has been found that the primers shown in the said patent examples tend to be softened by the dispersion of the invention, and also do not have as strong adhesion to the dispersion of the invention as good primer should have.

A preferred primer is as follows:

Primer Example I Parts by Primer Components Weight Resin content:

its

Vinyl acetate (13%)-.--

Malcic acid (1%) (3) Primer Resin B Solvent system:

Isophor ne The primer composition of the invention is applied to the metal surface and baked at a temperature of about 300 to about 400 F. for a time sufficient to expel the solvent, usually about 5 to 30 minutes. The foregoing Table II and Dispersion Examples I and II employed panels coated with the primer composition shown in Primer Example I above with a primer coating weight of about 1.5 mg./sq. in., and a primer bake of about 10 minutes at 390 F.

Pigments, dyes, and other materials may be added to the dispersions and primer compositions of the invention for decorative purposes and the like, without materially aifecting the significant characteristics of the composition. In addition, the dispersions of the invention may be modified with other additives, such as thermal stabilizers, to enhance special properties.

While I have described present preferred embodiments of the invention and methods of practicing the same, it will be recognized that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

I claim:

1. A fluid resin dispersion, capable of being spread on a surface and thereaf fuse" ating into a hard,

stable, continuous, tough and abrasion-resistant coating, comprising resin, plasticizer and volatile liquid dispersant components, said components consisting of (1) solid thermoplastic polyvinyl resin having an average molecular weight in excess of 20,000 and made from vinyl chloride in major amount, (2) plasticizer for the said resin, and (3) volatile liquid dispersant material consisting essentially of mixed aromatic alkyl substituted polynuclear hydrocarbons having a composite specific gravity of about one, a mixed aniline point of about 26 to about 30 C., and a distillation range of about 150 C. to about 450 C., and being characterized by having a series of substantially equal components by weight which have a series of respective boiling points increasing by substantially even increments, the plasticizer component (2) constituting about 5% to about 25% of the combined weight of the resin and plasticizer components (1) and (2), and the volatile liquid dispersant component (3) constituting about. 35% to about 55% of the total weight of components (1), (2) and (3), said composition having a viscosity in the range of about 30 seconds to about 300 seconds in No. 4 Ford cup at 80 F., being capable of being applied in a single coating to a film thickness, after fusing, of between 1 mil and about 20 mils, and being capable, when baked at 425 F. for 5 minutes, of releasing most of the said material (3) to the atmosphere without blistering the fused film.

2. A fluid resin dispersion as claimed in claim 1 in which the range of distillation of said dispersant extends over a span of at least substantially 193 C. between said upper and lower limits of distillation temperature.

3. A fluid resin dispersion in accordance with claim 1 in which the volatile liquid dispersant material (3) has a mixed aniline point of about 28, and a distillation range of about 205 to about 398 C.

4. A fluid resin dispersion in accordance with claim 3 in which the resin component (1) is polyvinyl chloride, and the plasticizer component is dioctyl phthalate.

5. A fluid resin dispersion in accordance with claim 4 in which the proportions by weight of components (1), (2) and (3) are about 44.7/9.1/46.2.

6. A fluid resin dispersion in accordance with claim 4 in which the proportions by weight of components (1), (2) and (3) are about 51.7/5.7/42.6.

7. The process of coating a metal surface, comprising applying the fluid resin dispersion of claim 1 thereon, and baking the coated surface at a temperature of at least 400 F. whereby coatings may be produced containing less than about 25% of'plasticizer components based on the combined weight of resin and plasticizer and whereby coatings having a thickness in excess of 3 mils may be produced in a single application Without developing film blisters and similar imperfections.

8. An article having a metal surface coated in accordance with the process of claim 7.

9. A fluid resin dispersion, capable of being spread on a surface and thereafter fused by heating into a hard, stable, continuous, tough and abrasion-resistant coating, comprising resin, plasticizer, and volatile liquid dispersant components, said components consisting of (1) solid thermoplastic polyvinyl resin having an average molecular weight in excess of 20,000 and made from vinyl chloride in major amount, (2) plasticizer for said resin, and (3) volatile liquid dispersant material consisting essentially of mixed aromatic alkyl substituted polynuclear hydrocarbons having a composite specific gravity of about one, a mixed aniline point of about 26 to about 30 C., and a distillation range of about 150 C. to about 450 C., the plasticizer component (2) constituting about 5% to about 25% of the combined weight of the resin and plasticizer components (1) and (2), and the volatile liquid dispersant component (3) constituting about 35 to about of the total weight of components (1), (2), and (3), said composition having a viscosity in the range of about 30 seconds to about 300 seconds in No. 4 Ford cup at B, being capable, when baked at 425 F. for 5 minutes, of releasing most of the said material (3) to atmosphere. 7

10. The process of coating a metal surface, comprising applying the fluid resin dispersion of claim 9 thereon and baking the coated surface at a temperature of at least 400 F. whereby coatings may be produced containing less than about 25% of plasticizer components based on the combined weight of resin and plasticizer.

References Cited in the file of this patent UNITED STATES PATENTS OTHER REFERENCES Ellis: Synthetic Resins and their Plastics, published by the Chemical Catalog Co. Inc., 1923 (page relied on). 

9. A FLUID RESIN DISPERSION, CAPABLE OF BEING SPREAD ON A SURFACE AND THEREAFTER FUSED BY HEATING INTO A HARD, STABLE, CONTINUOUS, TOUGH AND ABRASION-RESISTANT COATING, COMPRISING RESIN, PLASTICIZER, AND VOLTAILE LIQUID DISPERSANT COMPONENTS, SAID COMPONENTS CONSISTING OF (1) SOLID THERMOPLASTIC POLYVINYL RESIN HAVING AN AVERAGE MOLECULAR WEIGHT IN EXCESS OF 20,000 AND MADE FROM VINYL CHLORIDE IN MAJOR AMOUNT, (2) PLASTICIZER FOR SAID RESIN, AND (3) VOLATILE LIQUID DISPERSANT MATERIAL CONSISTING ESSENTIALLY OF MIXED AROMATIC ALKYL SUBSTITUTED POLYNUCLEAR HYDROCARBONS HAVING A COMPOSITE SPECIFIC GRAVITY OF ABOUT ONE, A MIXED ANILINE POINT OF ABOUT 26* TO ABOUT 30* C., AND A DISTILLATION RANGE OF ABOUT 150*C. TO ABOUT 450*C., THE PLASTICIZER COMPONENT (2) CONSTITUTING ABOUT 5% TO ABOUT 25% OF THE COMBINED WEIGHT OF THE RESIN AND PLASTICIZER COMPONENTS (1) AND (2), AND THE VOLATILE LIQUID DISPERSANT COMPONENT (3) CONSTITUTING ABOUT 35% TO ABOUT 55% OF THE TOTAL WEIGHT OF COMPONENTS (1), (2), AND (3), SAID COMPOSITION HAVING A VISCOSITY IN THE RANGE OF ABOUT 30 SECONDS TO ABOUT 300 SECONDS IN NO. 4 FORD CUP AT 80*F., BEING CAPABLE, WHEN BAKED AT 425* F. FOR 59 MINUTES, OF RELEASING MOST OF THE SAID MATERIAL (3) TO ATMOSPHERE. 